Note: Descriptions are shown in the official language in which they were submitted.
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EXTRACTIVE CONTINUOUS AMMONIA MONITORING SYSTEM
Field of the Invention
[001] The invention relates generally to continuously monitoring a gas stream
to
determine the ammonia concentration by extracting gas samples from one or more
locations of an apparatus and analyzing the samples by tunable diode laser
absorption spectroscopy.
Background of the Invention
[002] To assess the performance of a number of processes in which urea or
ammonia are employed, it is often necessary to have the ability to determine
how
much ammonia is in a process or effluent stream. Traditionally, samples have
been
extracted an analyzed by chemiluminescent techniques, resulting in extended
lag
times between sample acquisition and analysis. These methods also lacked a
desired precision at low concentrations because they relied upon assumptions
to
make the necessary calculations.
[003] Recently, interest has turned to tunable diode laser (TDL) absorption
spectroscopy. In a typical TDL installation, the transmitter and receiver are
mounted
directly to the ductwork. Since ammonia can convert to other compounds or be
absorbed in ash at temperatures less than 500 F, the ideal installation
location for a
TDL is upstream of the air heater. Installations of this type are difficult
for a variety of
reasons. Access is frequently difficult due to limited space existing between
the
economizer or catalyst outlet and the air heater inlet. Walkways are
frequently
absent. TDL's rely upon the line of sight between the transmitter and
receiver, with a
longer distance aiding accuracy at low concentrations. However, as the
distance
increases, the required alignment of the device becomes more
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difficult. Thermal cycles can also affect this alignment. Ash loading degrades
the signal and
in high ash environments, a longer TDL path length may not be possible.
Maintenance is
frequently difficult due to the instruments installed, location and the
challenges with access.
[004] TDL's measure the ammonia concentration on a line of sight path between
a
transmitter and a receiver. If the gas flow is stratified and the ductwork is
large, this
ammonia concentration may not be indicative of the actual, overall ammonia
concentration.
For this reason, on larger units or units with multiple ducts, a typical TDL
installation may
require more than one transmitting and receiving unit.
[005] Many commercial processes use extractive techniques to obtain samples of
off-gas
from the exhaust. The extracted gas is typically cooled and then analyzed
using mass
spectrometry or non-dispersive infrared absorption methods or chemical cells.
However,
the steps required to obtain a sample of the off-gas from extractive
techniques can result in
time delays in acquiring the data. By contrast, a process using real time
sensors could obtain
selective measurements of the off-gas constituents and provide adjustment of
the inputs to
a furnace on a continuous feedback loop. In one example of a continuous
extractive
analysis, WO 97/499979 to Frish, et al., describes a TDL system to monitor
trace
concentrations (e.g., on the order of one part per million) of ammonia in
gases extracted
from coal-fired utility boilers. The system includes a filter to remove
particulates and a
heater and temperature sensors that maintain the temperature of extracted
gases. The
device illustrated employs a Herriot cell to magnify TDL sensitivity in a
small foot print, but
this is not an ideal arrangement for use in obtaining accurate readings from a
utility boiler
where gas (and particulate) component compositions can vary across any given
cross
section.
[006] Both selective noncatalytic NO reduction (SNCR) and selective catalytic
NOx
reduction (SCR) processes used for controlling nitrogen oxides release from
power plants
and other combustors, employ ammonia either directly or indirectly as a NO,(-
reducing
reagent. It must be fed at the right concentrations and temperatures with
regard to the NOx
concentration to assure effective NO control without excessive ammonia slip.
There is
always a delicate balance, and control systems must have accurate information
to assure
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effective operation to comply with all regulations and guarantees as well as
to avoid
the practical problems of ammonium bisulfate production.
[007] What is needed is a system designed to solve the difficulties of a
typical TDL
installation. A useful system would be capable of sampling gases over a broad
array
of locations through probes designed and operated to assure that extracted gas
samples can be taken that are representative of actual operation conditions.
[008] There is a present need for a process, apparatus and system that will
enable
the realtime analysis of ammonia concentration in a process or effluent
stream.
Summary of the Invention
[009] The present invention provides processes, apparatus and systems for
measurement of ammonia in a process or effluent stream.
[009a] According to one aspect of the present invention, there is provided a
process
for continuously monitoring ammonia in an apparatus utilizing flowing gas
streams
containing ammonia, comprising: a. providing at least one hollow probe, each
comprising a hollow tube having an internal passage defined by a tube wall
having at
least one opening through the tube wall and means for connecting the internal
passage to an intake line; b. locating at least one of said probes within the
flowing
gas stream positioned to permit communication between the internal passage in
the
tubes with the gas in the flowing gas stream; c. creating a negative pressure
differential between each internal passage of each probe and the flowing gas
stream;
d. directing flow of gases from the flowing gas stream through a sample path
positioned between two sight glasses, one in front of a transmitter for a
tunable diode
laser at one end and one in front of a receiver at an opposite end, of the
path for the
tunable diode laser, to isolate the transmitter and receiver from the gas
stream;
e. maintaining the flow rate of gases through the sample path at a sufficient
rate that
the temperature of the gases in the sample path is maintained at a
predetermined
value; f. directing a beam of light, tuned to a selected wave length, from the
transmitter through the gas stream in the sample path to the receiver and
generating
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a signal representative of the light beam received at the receiver; g. based
on the
signal, using a logic and computation unit to calculate the concentration of
ammonia
in the gas stream.
[010] In one aspect, a process is provided for continuously monitoring ammonia
(or
other gas species) in an apparatus utilizing flowing gas streams containing
ammonia,
comprising: providing at least one (preferably a plurality) of hollow sampling
probe(s),
each comprising a hollow tube having an internal passage defined by a tube
wall
having at least one opening through the tube wall and means for connecting the
internal passage to an intake line; locating a plurality of said probes within
the flowing
gas stream positioned to permit communication between the internal passage in
the
tubes with the gas in the flowing gas stream; providing at least one valve for
each
hollow probe (in the case of a plurality) to control gas flow through a probe;
creating a
negative pressure differential between each internal passage of each probe and
the
flowing gas stream; directing flow of gases from the flowing gas stream
through a
sample path positioned between a transmitter and a receiver for a tunable
diode
laser; maintaining the temperature of the gases in the sample path at a
predetermined value; directing a beam of light, tuned to a selected wave
length (e.g.,
a narrow band), from the transmitter through the gas stream in the sample path
to the
receiver and generating a signal representative of the received signal; based
on the
signal calculating the concentration of ammonia in the gas stream; and,
preferably,
utilizing the concentration of ammonia as calculated to control one or more
operational parameters.
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[011] In a preferred aspect the sample stream is redirected from the sample
path to
recombine with the flowing gas stream.
[012] In another aspect, an apparatus is provided, comprising: at least one
(preferably a
plurality) of hollow sampling probe(s), each comprising a hollow tube having
an internal
passage defined by a tube wall having at least one opening through the tube
wall and means
for connecting the internal passage to an intake line; means for locating a
plurality of said
probes within the flowing gas stream positioned to permit communication
between the
internal passage in the tubes with the gas in the flowing gas stream; at least
one valve for
each hollow probe (in the case of a plurality) to control gas flow through a
probe; means for
creating a negative pressure differential between each internal passage of
each probe and
the flowing gas stream; means for directing flow of gases from the flowing gas
stream
through a sample path positioned between a transmitter and a receiver for a
tunable diode
laser; means for maintaining the temperature of the gases in the sample path
at a
predetermined value; means for directing a beam of light, tuned to a selected
wave length,
from the transmitter through the gas stream in the sample path to the receiver
and
generating a signal representative of the received signal; means for, based on
the signal,
calculating the concentration of ammonia in the gas stream; and, preferably,
means for
utilizing the concentration of ammonia as calculated to control one or more
operational
parameters.
[013] In a further aspect, the invention provides a system employing the
process and
apparatus as disclosed.
[014] Other and preferred aspects of the invention are described below.
Description of the Drawings
[015] The accompanying drawings, which are incorporated in and constitute a
part of this
description, illustrate presently preferred embodiments of the invention, and
together with
the detailed description of the preferred embodiments given below, serve to
explain the
principles of the invention. As shown throughout the drawings, like reference
numerals
designate like or corresponding parts.
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[016] Fig. 1 is a schematic diagram of a combustion installation that takes
advantage of the
present invention employing a preferred embodiment of the process and system
of the
invention.
[017] Fig. 2 is a schematic diagram showing greater detail of aspects of a
system of the
invention of the type shown in Fig. 1.
[018] Fig. 3 is a cross section taken along line 3-3 in Fig. 1, showing a
possible arrangement
of sampling probes within a conduit containing a flowing gas stream of gases
to be analyzed.
[019] Fig. 4 is a cross section of a sampling probe taken along line 4-4 in
Fig. 3.
Detailed Description of the Invention
[020] In describing the present invention, reference is made to the
drawings, wherein a
simplified, preferred embodiment is shown schematically. The drawings and the
process
and apparatus they represent will be described briefly below.
[021] As noted above, a gas stream from a combustor has not been easily
susceptible to
continuous, accurate analysis for target species like ammonia by available
equipment. The
invention addresses this concern and provides a simple, reliable, low-cost
solution.
[022] Fig. 1 is a schematic diagram of a combustion installation that takes
advantage of
the present invention to analyze a combustion effluent for ammonia slip, i.e.,
the ammonia
that is left after SNCR or SCR treatment of exhaust gases by either injecting
ammonia itself
or another chemical used to provide active NO reduction species.
[023] The combustion installation includes a combustor 10 having burners
that provide
thermal heat in combustion zone 12 by burning fuel from a source not shown
with air
supplied by duct work 14. Hot combustion gases will pass through the furnace
10 in the
direction indicated by the arrows, and the heat from combustion is transferred
to heat
exchangers 16 and 18 prior to passing into a selective catalytic reduction
(SCR) reactor 20
wherein NO created during combustion can be treated with a NO-reducing agent
such as
ammonia or gasified urea (including ammonia and HNCO) to convert the NO to
nitrogen
and water. The NO-reducing agent is supplied, for example, by means of reagent
storage
tank 22 and injection grid 24. Alternatively, many installations will benefit
from selective
non catalytic reduction (SNCR) using urea alone or other NO-reducing agent at
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temperatures, e.g., as taught by Epperly, et al., in U. S. Patent No.
5,057,293, without
requiring the reactor 20.
[024] Following SCR reactor 20, the combustion gases will flow through an
air-to-air
heat exchanger 26, which is used to preheat outside air supplied via duct 28
for delivery to
the combustion zone 12 via line 14. The combustion gases leaving the heat
exchanger 26 are
cooled significantly by the time they are passed through duct work 29 to
electrostatic
precipitator (ESP) 30 wherein particulates are collected prior to passing the
gases up stack
32. This is a highly-simplified version of actual industrial or utility
combustors and effluent
treatment processes, but illustrates a workable scheme.
[025] A tunable diode laser gas analyzer apparatus of the invention 40 is
shown generally
in Fig. 1 to include a support structure 42 for holding a plurality of hollow
probes 44 (see Fig.
3 for a schematic arrangement). An intake line 46 is provided to direct a flow
of gases to
analyzer apparatus 40 from the flowing gas stream following the SCR reactor 20
to the
probes 44.
[026] Each of the probes 44 comprises a hollow tube having an internal passage
47 defined
by a tube wall 45 having at least one opening 49 through the tube wall and
means for
connecting the internal passage to noted intake line 46. Once analyzed by
passing through
apparatus 40, the gases are returned via line 48 to the stream of exit gases,
preferably just
downstream of the sampling point (not shown), but can be later say in duct 29
(as
illustrated). Lines 46 and 48 are shown schematically only and are preferably
stainless steel
pipe, which tends to be rigid. If suitable flexible tubing is available, it
can be used.
[027] The invention enables simplified and real-time analysis of the stream
for ammonia
taken from a stream of gases flowing from the SCR unit 20 in duct 21, via
intake line 46 to a
suitable connection, such as intake flange 46 on apparatus 40, as best seen in
Fig. 2. As will
be apparent from the discussion of Fig. 3, the probes 44 can be fitted with
valves and
adjusted with the duct 21 to enable taking samples from particular locations,
representative
of the entire cross section, or an average of a particular cross section. A
fan 50 is provided to
pull the gases through apparatus 40 and return them to a suitable duct, say
29, via line 48
attached by means of a suitable connection, such as flange 48. The gases to be
analyzed are
drawn into sample path 52, typically a stainless steel tube, by a negative
pressure
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differential between each internal passage of each probe 44 and the flowing
gas stream in
duct 21. The sample path 52 is insulated, e.g., as shown partially at 54, to
maintain the gas
temperature and to avoid injury to operators. A preferred length of the sample
path 52 is
twelve feet but this may vary as requirements dictate, e.g., from about 3 to
about 20 feet.
[028] The sample path 52 has sight glasses 56 and 56 located on opposite ends,
with 56
being at the transmitter end and 56' being at the receiver end to protect the
transmitter 60
and the receiver 62 for a tunable diode laser from any contamination by the
hot gases being
directed through the sample path. The sight glasses physically separate the
transmitter 60
and the receiver 62 from the interior of the sample path 52 while still
permitting the
transmitter 60 to direct a beam of light, tuned to a selected wave length, and
for the
receiver 62 to receive it for analysis by logic and computation unit 64.
Electrical power to
the transmitter and control signals to and from the logic and computation unit
64 can be
supplied via electrical lines shown generally as 66. A supply of cooling air,
not shown, is
preferably provided to each of the transmitter 60 and the receiver 62 units to
maintain a
safe operating temperature.
[029] The temperature of the gases in the sample path 52 is easily maintained
at a
predetermined value, e.g., at least about 450 F, and preferably within the
range of from
500 to 600 F, without any additional heat by maintaining a suitably high
flow rate through
the path 52. The sample path can be heated by heaters, not shown, that can be
embedded
in insulation 54, if necessary. It is an advantage of the invention is that
the high flow rate of
hot gases makes heating unnecessary except in anomalous situations. In the
exemplary
situation of a two inch diameter sample chamber path 52, which is twelve feet
long, a flow
rate of 120 scfm (e.g., from 20 to 300 scfm) provides a complete exchange of
gases about
eight times per second. The entire system residence time will typically be
less than a
second. This assures the gases will not cool substantially. In a target system
residence time
will be between 0.2 and 5 seconds, e.g., about 1 second, preferably and that
the target
measurement volume residence time is within this range where temperatures can
be
maintained and extractive effectiveness retained, and preferably between 0.05
and 0.5
seconds. The high flow rate also can eliminate the need for a filter to remove
ash in
embodiments where the ash is never given the opportunity to collect. In
others, the use of a
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cyclone 68, receiving gas from line 46 and discharging it to the analyzer
apparatus 40, can
effectively handle significant ash loadings.
[030] The details of the wavelengths of light, electrical and temperature
requirements for
the particular tunable diode laser selected, will all be available from the
manufacturer. We
presently prefer Yokogawa TDLS200 analyzer, but there is no criticality in
this selection. The
analyzer is capable of directing a beam of light, tuned to a selected wave
length, typically
tuned within a narrow band (e.g., a resolution of less than 0.02 nm) of
wavelengths, from
the transmitter 60 through the gas stream in the sample path 52 to the
receiver 62 and
generating a signal representative of the received signal. Based on the
signal, the logic and
computation unit 64 is capable of calculating the concentration of ammonia in
the gas
stream, and will do so. Based on this signal representative of the ammonia
concentration, a
process controller, e.g., for the SCR reactor and ammonia supply will control
one or more
operational parameters.
[031] Detail and arrangement of the probes 44 are illustrated schematically in
Fig. 3, with
Fig. 4 showing a cross section of one probe 44 taken along line 4-4 in Fig. 3.
It can be seen
that each probe 44 comprises a hollow tube having an internal passage defined
by a tube
wall having at least one opening through the tube wall and means for
connecting the
internal passage to an intake line. Fig. 4 shows tube 44 having a central
opening 45 with a
hole 47 therethrough. As seen in Fig. 3, there can be a plurality of holes.
Means, which may
be simple brackets (represented by the outer dotted lines at 44 in Fig. 1, are
provided to
enable locating a plurality of the probes within the flowing gas stream in
duct 21 and to
position them effectively to permit communication between the internal passage
47 in the
tubes with the gas in the flowing gas stream in duct 21. At least one valve 70
is provided for
each hollow probe to control gas flow through a probe. By proper placement of
the probes
within duct 21, depending on the particular flow patterns that have been
determined by
suitable modeling, e.g., computational fluid dynamics or cold flow modeling,
the valves 70
can be operated manually or by a controller to take samples at predetermined
locations
within the duct 21. This will enable taking samples from particular locations,
samples
representative of the entire cross section, or samples that are an average of
a particular
cross section. It will be possible by judicious placement of the probes 44 and
operation of
the valves 70 to map the concentrations of ammonia at a plurality of load
settings and will
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permit continuous control. The invention provides the ability to test at
various locations
along the flue gas path as boiler load changes without the need to install
transmitter and
receiver pairs at each location to be tested. While lacking the full mapping
capability, it will
be possible to install the above apparatus with a single probe, without any
valve and still
take advantages of some aspects of the invention.
[032] Systems employing the process and apparatus combine the disclosed
features and
incorporate details as necessary for a wide variety of industrial
applications.
[033] The above description is for the purpose of teaching the person of
ordinary skill in
the art how to practice the invention. It is not intended to detail all of
those obvious
modifications and variations, which will become apparent to the skilled worker
upon
reading the description. It is intended, however, that all such obvious
modifications and
variations be included within the scope of the invention which is defined by
the following
claims. The claims are meant to cover the claimed components and steps in any
sequence
which is effective to meet the objectives there intended, unless the context
specifically
indicates the contrary.
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